YAMAHA XT660Z 2011 Service Manual

ITEM CHECKS PAGE
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 6-21
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
Clutch• Lubricate cable if necessary.
6-20
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-17, 6-25
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-25
• Check chain slack.
Drive chain• Adjust if necessary.
6-23, 6-24
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-17, 6-19
• Check air pressure.
• Correct if necessary.
Brake pedal• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.6-26
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-25
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-26
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals • Check operation.
and switches• Correct if necessary.—
FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
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ITEM CHECKS PAGE
Sidestand switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer check vehicle.3-19
FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-3
4
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EAU15951
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do
not understand, ask your Yamaha
dealer.
EWA10271
Failure to familiarize yourself with
the controls can lead to loss of
control, which could cause an acci-
dent or injury.
EAU45310
TIP
This model is equipped with a lean
angle sensor to stop the engine in
case of a turnover. To start the engine
after a turnover, be sure to turn the
main switch to “OFF” and then to
“ON”. Failing to do so will prevent the
engine from starting even though the
engine will crank when pushing the
start switch.
EAUS1950
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-20.
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “ ”.
WARNING
WARNING
OPERATION AND IMPORTANT RIDING POINTS
5-1
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ECAS0040
The following warning lights and
indicator lights should come on for
a few seconds, then go off.
Neutral indicator light
Turn signal indicator light
High beam indicator light
Engine trouble warning light
Coolant temperature warning
light
Immobilizer system indicator
light
ABS warning light (for ABS
model)
If a warning or indicator light does
not go off, see page 3-4 for the
corresponding warning and indica-
tor light circuit check.
2. Shift the transmission into the
neutral position.
TIP
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
3. Start the engine by pushing the
start switch. NOTICE: For maxi-
mum engine life, never accele-
rate hard when the engine is
cold!
[ECA11041]
TIP
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
TIP
The engine is warm when it quickly
responds to the throttle.
EAU16671
Shifting
1. Shift pedal
2. Neutral position
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly rai-
se it.
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
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ECA10260
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dama-
ging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follo-
wing tips to reduce fuel consumption:
Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
Do not rev the engine while shif-
ting down, and avoid high engine
speeds with no load on the engi-
ne.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cros-
sings).
EAU16841
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1600 km
(1000 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts
in the engine wear and polish them-
selves to the correct operating clea-
rances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAU17101
0–1000 km (0–600 mi)
Avoid prolonged operation above
4500 r/min. NOTICE: After 1000
km (600 mi) of operation, the
engine oil must be changed,
and the oil filter element repla-
ced.
[ECA11151]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above
6000 r/min.
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
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1600 km (1000 mi) and beyond
The vehicle can now be operated
normally.
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them and be burned.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn, increa-
sing the risk of a fuel leak and
fire.
Do not park near grass or other
flammable materials which
might catch fire.
WARNING
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
5-4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17243
Periodic inspection, adjustment, and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the vehicle owner/operator. The
most important points of vehicle ins-
pection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However,
depending on the weather, terrain,
geographical location, and individual
use, the maintenance intervals may
need to be shortened.
EWA10321
Failure to properly maintain the
vehicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EWA15121
Turn off the engine when perfor-
ming maintenance unless otherwi-
se specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while servi-
cing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more
information about carbon
monoxide.
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before tou-
ching them.
EAU17381
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-16).
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
WARNING
WARNING
WARNING
56P-F8199-E0 30/6/10 09:24 Página 47

TIP
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
PERIODIC MAINTENANCE AND ADJUSTMENT
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU46861
TIP
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK,
a mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
EAU46910
Periodic maintenance chart for the emission control system
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1*Fuel line• Check fuel hoses for cracks or
damage.√√√ √√
2Spark plug• Check condition.
• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√
4*Fuel injection• Adjust engine idling speed.√√ √ √ √ √
5*Mufflers and exhaust• Check the screw clamps for
pipeslooseness.√√ √ √ √
• Check the air cut-off valve, reed
6*Air induction systemvalve, and hose for damage.
√√√ √√
• Replace any damaged parts if
necessary.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1Air filter element• Replace.√√
2Clutch• Check operation.
• Adjust.√√ √ √ √
3*Front brake• Check operation, fluid level and
vehicle for fluid leakage.√√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
4*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
5*Brake hoses• Check for cracks or damage.√√√ √√• Replace. Every 4 years
• Check runout, spoke tightness
6*Wheelsand for damage.√√ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for
damage.
7*Tires• Replace if necessary.√√√ √√
• Check air pressure.
• Correct if necessary.
8*Wheel bearings• Check bearing for looseness or
damage.√√√ √
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